Superior Axle also hooked us up with a set of high-strength 30-spline Evolution axleshafts for the project. These shafts feature a dual heat-treatment process to improve durability. These shafts accept full circle clips and each has rolled splines that result in a 35-percent strength increase over traditional cut splines. The dark black color relates to the corrosion-resistant DuraCoat finish that prevents these shafts from ever looking like the original shown here. Another cool aspect of these shafts is the fact that Superior engineers them with equalizing-diameter profiles which allows the short side axle to have similar ductility as the long side. This means each side is equal in torsional strength. Therefore you shouldn't snap the short side just because it doesn't twist as much as the long side.
 Blue Torch Fab Works also...  Blue Torch Fab Works also sent us a pair of its TJ lower control-arm mounts. We like these because they are constructed from 3/16-inch-thick material versus the factory 1/16-inch-thick sheetmetal. They also include the "horseshoe" built in for cam bolt adjustment. With these units installed we won't have to worry about rock damage deforming the brackets. A gusset ensures both sides of the bracket remain square to one another. |  Superior's tube seals are...  Superior's tube seals are the perfect solution for those who like to play in the mud. These seals are constructed from billet aluminum and feature two rubber seals that ride against the axleshaft to prevent debris from entering the axletubes. Additionally a grease fitting that allows users to create a grease barrier between the two rubber gaskets. These seals install simply by pressing into the axletube prior to installing the shafts. A light layer of RTV silicone helps ensure they stay put. |  We had our friends at Custom...  We had our friends at Custom Coatings of Ukiah, California, powdercoat the high-steer arms and differential cover to ensure long-lasting good looks. When we returned the next day to pick up the parts, we were impressed with the uniform gloss black finish-almost too nice for a part of the rig that gets dirty. |
 We prefer Ultra Seal U-joints...  We prefer Ultra Seal U-joints from Quality Gear because of their unique internally sealed bearing caps. These joints are 30-percent stronger than regular Spicer-type joints and each is designed to perform optimally in wet environments. At just 30 bucks a pop, you simply can't beat the value of these U-joints. |  Prior to assembly we had the...  Prior to assembly we had the guys at NCD Painting of Ukiah, California, paint the axlehousing gloss black. In preparation for paint, the housing was sandblasted to remove any surface rust. After a night in the dryer booth, the housing looked brand new. |  Once welded in place and painted,...  Once welded in place and painted, the Blue Torch Fab Works lower control-arm mounts look as if they came installed from the factory. However, these units are three times stronger than the O.E. brackets. |
 Here you can see how the Stage...  Here you can see how the Stage 8 locking spindle nut is installed against the outer bearing of the hub assembly. |  The Eaton E-Locker requires...  The Eaton E-Locker requires that a small hole be drilled in the side of the differential housing to allow passage of the electrical connection for the locker actuator. | |
We opted to use genuine Amsoil synthetic gear lube because Amsoil claims its lubricants maintain viscosity better than other oils available today. We figure it was worth a try, seeing as this rig will likely see a lot of highway miles going forward. The proprietary additives in this lube are said to form an iron-sulfide barrier coating on gear surfaces, providing the superior defense against wear, pitting, and scoring. We'll update you on our results later towards the end of '09 and let you know what we think.
This is the completed Dana 30/44 hybrid axle just prior to installation in the TJ. Look for Part 2 of this project in the coming months. At that time we will address and upgrade the rear Dana 35 axle found under this Jeep with a similar build strategy, while showcasing some of the latest product offerings.